Discharge valve

ABSTRACT

A compressor assembly includes a shell which defines a discharge chamber. A discharge valve assembly is attached to the shell in communication with the discharge chamber. The discharge valve assembly includes a stamped or coined valve seat, a drawn tubular element and a stamped valve member. The stamping, drawing and coining operations used to manufacture the discharge valve assembly significantly reduce the manufacturing costs for the discharge valve assembly.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No.09/698,710 filed on Oct. 27, 2000, now U.S. Pat. No. 6,428,292, which isa divisional of application Ser. No. 09/237,692, filed Jan. 26, 1999,now U.S. Pat. No. 6,171,084 issued on Jan. 9, 2001. The disclosures ofthe above applications are incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates generally to discharge valves forcompressors. More particularly, the present invention relates to scrollcompressors incorporating discharge valves having stamped valve plates.

BACKGROUND AND SUMMARY OF THE INVENTION

Scroll type machines are becoming more and more popular for use ascompressors in both refrigeration as well as air conditioningapplications due primarily to their capability for extremely efficientoperation. Generally, these machines incorporate a pair of intermeshedspiral wraps, one of which is caused to orbit relative to the other soas to define one or more moving chambers which progressively decrease insize as they travel from an outer suction port toward a center dischargeport. An electric motor is provided which operates to drive the orbitingscroll member via a suitable drive shaft. Because scroll compressorsdepend upon a seal created between opposed flank surfaces of the wrapsto define successive chambers for compression, suction and dischargevalves are generally not required. However, when such compressors areshut down, either intentionally as a result of the demand beingsatisfied or unintentionally as a result of a power interruption, thereis a strong tendency for backflow of compressed gas from the system incombination with high pressure gas contained in the chambers and/ordischarge muffler to effect a reverse orbital movement of the orbitingscroll member and associated drive shaft. This reverse movement oftengenerates objectionable noise or rumble. Further, in machines employinga single phase drive motor, it is possible for the compressor to beginrunning in the reverse direction should a momentary power failure beexperienced.

In order to limit such reverse rotation, prior art scroll compressorshave incorporated ball type check valves at the point of connectionbetween the outer shell and the discharge line. While such ball typecheck valves have been effective to limit back flow of compressedrefrigerant, they have demonstrated a tendency to vibrate or chatterunder certain flow conditions thus presenting a further source ofobjectionable noise. Also, in severe situations, the chattering mayresult in damage or destruction of the ball stop and/or seat.Additionally, the occasional discharge of liquid through such ball typecheck valves further increases the possibility of damage thereto.

Other prior art scroll compressors incorporate disc type check valve inthe outlet from the outer shell which effectively prevents return flowof compressed gas from the refrigeration system and hence limits reverseorbital movement of the orbiting scroll member. Because reverse orbitalmovement is thus limited, the possibility of objectionable noise beinggenerated thereby upon shut down of the compressor is greatly reduced.The disc type discharge valve does not require any biasing means butrather operates to create a pressure differential thereacross whichmoves the disc between seated and unseated positions. The disc typedischarge valve provides an inexpensive, easily installed means toeffectively resist reverse movement of the orbiting scroll. Further,because a relatively large stop surface area is provided extendingaround the periphery of the valve member, the possibility of damage fromdischarge of liquid therethrough is greatly reduced.

While the above described disc valves have performed satisfactorily, themanufacture of the individual components of the disc type check valverequired the machining of a housing and the machining or powder metalforming of one or more of the valve components. Both of these formingoperations are relatively expensive leading to an increase in themanufacturing costs. The present invention overcomes the problemsassociated with the relatively expensive forming operations by providinga disc type check valve assembly where all of the components of thecheck valve assembly are manufactured by using a relatively lower coststamping process or a powdered metal process. In one embodiment, one ofthe valve members is integral with the shell of the compressor.

Other advantages and objects of the present invention will becomeapparent to those skilled in the art from the subsequent detaileddescription, appended claims and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings which illustrate the best mode presently contemplatedfor carrying out the present invention:

FIG. 1 is a side elevational view, partially in cross section of ahermetically sealed compressor incorporating a disc type discharge valveassembly in accordance with the present invention;

FIG. 2 is an enlarged cross section view of the disc type dischargevalve assembly shown in FIG. 1;

FIG. 3 is a cross section view of the discharge valve assembly shown inFIG. 2 taken along line 3—3 thereof;

FIG. 4 is a cross section view of the discharge valve assembly shown inFIG. 2 taken along line 4—4 thereof;

FIG. 5 is an enlarged cross section similar to that of FIG. 2illustrating a disc type discharge assembly in accordance with anotherembodiment of the present invention;

FIG. 6 is an enlarged cross section similar to that of FIG. 2illustrating a disc type discharge assembly in accordance with anotherembodiment of the present invention;

FIG. 7 is an enlarged cross section similar to that of FIG. 2illustrating a disc type discharge assembly in accordance with anotherembodiment of the present invention;

FIG. 8 is an enlarged cross section similar to that of FIG. 2illustrating a disc type discharge assembly in accordance with anotherembodiment of the present invention;

FIG. 9 is an enlarged cross section similar to that of FIG. 2illustrating a disc type discharge assembly in accordance with anotherembodiment of the present invention;

FIG. 10 is an enlarged cross section similar to that of FIG. 2illustrating a disc type discharge assembly in accordance with anotherembodiment of the present invention;

FIG. 11 is an enlarged cross section similar to that of FIG. 2illustrating a disc type discharge assembly in accordance with anotherembodiment of the present invention;

FIG. 12 is an enlarged cross section similar to that of FIG. 2illustrating a disc type discharge assembly in accordance with anotherembodiment of the present invention;

FIG. 13 is an enlarged cross section similar to that of FIG. 2illustrating a disc type discharge assembly in accordance with anotherembodiment of the present invention;

FIG. 14 is an enlarged cross section similar to that of FIG. 2illustrating a disc type discharge assembly in accordance with anotherembodiment of the present invention;

FIG. 15 is an enlarged cross-section similar to that of FIG. 14illustrating an alternative welding operation; and

FIG. 16 is an enlarged cross section similar to that of FIG. 2illustrating a disc type discharge assembly in accordance with anotherembodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The present invention is illustrated for exemplary purposes inconjunction with a hermetically sealed scroll compressor. It is to beunderstood that the present invention is not limited to a scrollcompressor and that it is possible to use the disc type discharge valveassembly of the present invention on virtually any type of motorcompressor or similar machine.

Referring now to the drawings in which like reference numerals designatelike or corresponding parts throughout the several views, there is shownin FIG. 1, a scroll compressor including the disc type discharge valveassembly in accordance with the present invention which is designatedgenerally by the reference numeral 10. Compressor 10 is comprised of ahermetic shell assembly 12, a compressor section 14 and a motor drivesection 16. Hermetic shell assembly 12 is comprised of a lower shell 18,an upper cap 20, a bottom cover 22 and a partition plate 24. Bottomcover 22, lower shell 18, partition plate 24 and upper cap 20 arefixedly and sealingly attached in the manner shown in FIG. 1 by weldingduring the assembly of compressor 10 to form a sealed suction chamber 26and a sealed discharge chamber 28. Hermetic shell assembly 12 furtherincludes a suction inlet fitting 30 in communication with suctionchamber 26 and a disc type discharge valve assembly 32 in communicationwith discharge chamber 28.

Compressor section 14 is comprised of a non-orbiting scroll member 34,an orbiting scroll member 36 and a bearing housing 38. Non-orbitingscroll member 34 includes an end plate and body 40 having a chamber 42within which is disposed a spiral wrap 44. Non-orbiting scroll member 34further includes a plurality of embossments 46 which are adapted to beattached to bearing housing 38 by a plurality of bolts 48.

Orbiting scroll member 36 includes an end plate 50 and a spiral wrap 52which extends upright from end plate 50 into chamber 42. Spiral wrap 52is meshed with spiral wrap 44 on non-orbiting scroll member 34 in theusual manner to form in combination with bearing housing 38 a portion ofcompressor section 14 of compressor 10. At least one closed chamber 54is defined by meshing wraps 44 and 52 with a discharge port 56 formed inthe central portion of non-orbiting scroll member 34. Discharge port 56communicates with discharge chamber 28 formed by partition plate 24 andupper cap 20.

Bearing housing 38 includes a plurality (typically 3 or 4) of radiallyoutwardly extending arms 58 affixed to hermetic shell assembly 12. Arms58 of bearing housing 38 align with embossments 46 on non-orbitingscroll member 34 and they each include a threaded hole 60 for acceptingbolts 48 to attach non-orbiting scroll member 34 to bearing housing 38as described above.

Compressor section 14 further includes a crankshaft 62 having aneccentric shaft portion 64. Eccentric shaft portion 64 is coupled toorbiting scroll member 36 through a drive bushing and bearing assembly66. An upper counter balance weight 68 is fixed to crankshaft 62.Crankshaft 62 extends into motor drive section 16 and is supported atits lower end by a lower bearing assembly 70. Lower bearing assembly 70includes a plurality (typically 3 or 4) of radially outwardly extendingarms 72 fixedly secured to shell assembly 12. A central portion of lowerbearing assembly 70 includes an elongated bore 76 within which isdisposed a journal bearing 78 which receives the lower end of crankshaft62.

Motor drive section 16 comprises a motor stator 80 and a motor rotor 82.Motor stator 80 is securely mounted within lower shell 18 of shellassembly 12, preferably by press fitting. Motor rotor 82 is coupled tocrankshaft 62 and with crankshaft 62 rotates within motor stator 80.Motor stator 80 and motor rotor 82 thus operate to rotate crankshaft 62to cause orbiting scroll member 36 to orbit with respect to non-orbitingscroll member 34 thereby causing the at least one closed chamber 54 toform at an outer suction port and for chamber 54 to progressivelydecrease in size as it travels towards center discharge port 56 where itis discharged into discharge chamber 28. A floating seal 84 seals theinterface between suction chamber 26 and discharge chamber 28.

The embodiments shown in FIGS. 2-9 illustrate a valve plate whichdefines a valve seat which has been formed by a powdered metal, astamping and/or coining process. The coining operation for the valveseat is an inexpensive process which produces a finished planar surfacefor the valve seat allowing the valve member to sealingly engage thevalve seat to prohibit flow of the discharge gas. Thus, a significantcost savings and simplification of the compressor assembly can beachieved by incorporating the coining of the valve seat.

Referring now to FIGS. 2-4, discharge check valve assembly 32 comprisesa discharge valve plate 90, an elongated tubular member 92 and a valvemember 94. Discharge valve plate 90 is formed as an integral part ofupper cap 20 of shell assembly 12 by a stamping and/or coiningoperation. Valve plate 90 has a plurality (three as shown in FIG. 3) ofsubstantially identical arcuate cutout portions 96 provided therein. Asubstantially planar surface portion surrounds the plurality of cutoutportions 96 to form a valve seat 98 for sealing engagement with valvemember 94.

Elongated tubular member 92 has a generally radially outwardly extendingannular flange 100 which is adapted to abut and be welded to the outersurface of upper cap 20. In order to aid in the welding process andensure a secure fluid-tight seal, an annular axially outwardlyprojecting rib 102 is provided on flange 100. During the weldingoperation, rib 102 becomes sacrificial to supply a portion of the weldmaterial as is well known in the art. Tubular member 92 can be welded toupper cap 20 by friction welding, resistance welding, laser welding,electron beam welding or any other welding technique know in the art.Tubular member 92 has a generally radially inwardly extending flange 104which with valve plate 90 forms a chamber 106 within which valve member94 is located. Flange 104 provides an annular stop surface or shoulderfor restricting the movement of valve member 94. The end of tubularmember 92 opposite to flange 100 defines an enlarged diameter end 108which is adapted to be connected to a suitable conduit (not shown) ofthe refrigeration system with which compressor 10 is to be utilized.Thus, tubular member 92 provides a discharge fluid passage betweendischarge chamber 28 and the refrigeration system.

Valve member 94 is disposed within chamber 106 and is sized so as to befreely movable between valve seat 98 and flange 104. Valve member 94 hasa center opening 110 of substantial diameter through which thecompressed fluid is allowed to flow when valve member 94 is spaced fromvalve seat 98 or when valve member 94 abuts flange 104. When valvemember 94 abuts valve seat 98, the diameter of opening 110 is such thatfluid communication through the plurality of cutout portions 96 isprohibited.

Preferably, tubular member 92 and valve member 94 are fabricated fromsheet metal such as steel whereas valve plate 90 is formed as anintegral part of upper cap 20. Tubular member 92 may also be formed fromcopper or other materials as dictated by the system requirements withwhich compressor 10 is to be utilized.

In operation, with compressor 10 running, the pressure within dischargechamber 28 will be above the pressure that exists down stream ofdischarge check valve assembly 32 and thus, the compressed fluid willflow through openings 96 to thereby cause valve member 94 to movetowards flange 104, or to an open position, whereby the compressed gasmay flow through opening 110 to the refrigeration system. Opening 110 isslightly smaller than the inside diameter of tubular member 92 and thusa pressure differential will exist across valve member 94 which willserve to retain valve member 94 against flange 104 thus preventing thepossibility of chattering. When compressor 10 is shut down, the pressurewithin discharge chamber 28 may decrease below the pressure that existsdownstream of valve assembly 32. Under these conditions, the pressuredrop across opening 110 in valve member 94 will result in a net forcethereon causing valve member 94 to move against valve seat 98 of valveplate 90, or to a closed position, where valve member 94 overliesopenings 96 thereby preventing backflow of the compressed gas intodischarge chamber 28.

Referring now to FIG. 5, a discharge valve assembly 132 according toanother embodiment of the present invention is illustrated. Valveassembly 132 is shown welded to an upper cap 120 having an aperture 122extending therethrough. Upper cap 120 is interchangeable with upper cap20 shown in FIGS. 1-4. Valve assembly 132 comprises a discharge valveplate 140, an elongated tubular member 142 and valve member 94.Discharge valve plate 140 is formed as a separate component by astamping and/or coining operation and has the plurality of cutoutportions 96 therein as well as valve seat 98 for sealing engagement withvalve member 94. Discharge valve plate 140 has a generally radiallyoutwardly extending annular flange 146 which is adapted to abut and bewelded to tubular member 142. In order to aid in the welding process andensure a secure fluid tight seal, an axially extending rib 148 isprovided on flange 146. During the welding operation, rib 148 becomessacrificial to supply a portion of the weld material as is well known inthe art.

Tubular member 142 has a generally radially outwardly extending annularflange 150 which is adapted to abut both annular flange 146 and theinner surface of upper cap 120. Annular flange 150 is also adapted to bewelded to the inner surface of upper cap 120. In order to aid in thewelding process and ensure a secure fluid tight seal, an axiallyoutwardly projecting rib 152 is provided on flange 150. During thewelding operation, rib 152 becomes a sacrificial to supply a portion ofthe weld material as is well known in the art. Rib 152 is shown as beinglarger in diameter than rib 148. It is within the scope of the presentinvention to have rib 152 smaller in diameter than rib 148 or to haverib 152 as the same diameter as rib 148 in order to facilitate thewelding of valve plate 140 to tubular member 142 and tubular member 142to the inner surface of upper cap 120. Tubular member 142 has agenerally radially inwardly extending flange 154 which with valve plate140 forms a chamber 156 within which valve member 94 is located. Flange154 provides an annular stop surface or shoulder for restricting themovement of valve member 94. The end of tubular member 142 opposite toflange 150 defines enlarged diameter end 108 which, as described above,is adapted to be connected to the suitable conduit of the refrigerationsystem with which compressor 10 is to be utilized.

Valve member 94 is disposed within chamber 156 and is sized so as to befreely movable between valve seat 98 and flange 154. The movement,function and operation of valve member 94 in discharge valve assembly132 is the same as that described above for the embodiment shown inFIGS. 1-4.

Referring now to FIG. 6, a discharge valve assembly 132′ according toanother embodiment of the present invention is illustrated. Valveassembly 132′ is shown welded to upper cap 120 extending throughaperture 122. Valve assembly 132′ is similar to valve assembly 132 shownin FIG. 5 except that discharge valve plate 140 has been replaced withdischarge valve plate 140′. Discharge valve plate 140′ is also formed bya stamping and/or coining operation and is similar to discharge valveplate 140 except that the center portion of valve plate 140′ includes adomed contour 160 in place of the generally planar center portion ofvalve plate 140. Domed contour 160 provides rigidity to valve seat 98allowing it to maintain its generally planar characteristic and thusimproving the sealing relation between valve seat 98 and valve member94. The function and operation of valve assembly 132′ is the same asvalve assembly 132 shown in FIG. 5.

Referring now to FIG. 7, a discharge valve assembly 182 according toanother embodiment of the present invention is illustrated. Valveassembly 182 is shown welded to upper cap 120 extending out of aperture122. Valve assembly 182 comprises a discharge valve plate 190, anelongated tubular member 192 and valve member 94. Discharge valve plate190 is a generally cup shaped plate formed as a separate component by astamping and/or coining operation and has the plurality of cutoutportions 96 therein as well as valve seat 98 for sealing engagement withvalve member 94. Discharge valve plate 190 has a generally radiallyoutwardly extending annular flange 196 which is adapted to abut and bewelded to the outer surface of upper cap 120. In order to aid in thewelding process and ensure a secure fluid tight seal, an axiallyextending rib 198 is provided on flange 196. During the weldingoperation, rib 198 becomes sacrificial to supply a portion of the weldmaterial as is well known in the art.

Tubular member 192 has a generally outwardly extending annular flange200 which is adapted to abut and be welded to annular flange 196 ofvalve plate 190. In order to aid in the welding process and ensure asecure fluid tight seal, an axially outwardly projecting rib 202 isprovided on flange 200. During the welding operation, rib 202 becomessacrificial to supply a portion of the weld material as is well known inthe art. Rib 202 is shown as being larger in diameter than rib 198. Itis within the scope of the present invention to have rib 202 smaller indiameter than rib 198 or to have rib 202 the same diameter as rib 198 inorder to facilitate the welding the tubular member 192 to valve plate190 and valve plate 190 to the outer surface of upper cap 120. Tubularmember 192 has a generally radially inwardly extending flange 204 whichwith valve plate 190 forms a chamber 206 within which valve member 94 islocated. Flange 204 provides an annular stop surface or shoulder forrestricting the movement of valve member 94. The end of tubular member192 opposite to flange 200 defines enlarged diameter end 108 which, asdescribed above, is adapted to be connected to the suitable conduit ofthe refrigeration system with which compressor 10 is to be utilized. Inorder to ensure fluid tightness between valve plate 190 and tubularmember 192, a laser welding operation can be performed circumferentiallyaround the seam 206 formed by the mating of valve plate 190 and tubularmember 192.

Valve member 94 is disposed within chamber 206 and is sized so as to bereadily movable between valve seat 98 and flange 204. The movement,function and operation of valve member 94 in discharge valve assembly182 is the same as that described above for the embodiment shown inFIGS. 1-4.

Referring now to FIG. 8, a discharge valve assembly 232 according toanother embodiment of the present invention is illustrated. Valveassembly 232 is shown welded to upper cap 120 on opposite sides ofaperture 122. Valve assembly 232 comprises a discharge valve plate 240,an elongated tubular member 242 and valve member 94. Discharge valveplate 240 is a generally cup shaped plate formed as a separate componentby a stamping and/or coining operation and has the plurality of cutoutportions 96 therein as well as valve seat 98 for sealing engagement withvalve member 94. Discharge valve plate 240 has a generally radiallyoutwardly extending annular flange 246 which is adapted to abut and bewelded to the inner surface of upper cap 120. In order to aid in thewelding process and ensure a secure fluid tight seal, an axiallyextending rib 248 is provided on flange 246. During the weldingoperation, rib 248 becomes sacrificial to supply a portion of the weldmaterial as is well known in the art.

Tubular member 242 has a generally outwardly extending annular flange250 which is adapted to abut and be welded to the outer surface of uppercap 120. In order to aid in the welding process and ensure a securefluid tight seal, an axially outwardly projecting rib 252 is provided onflange 250. During the welding operation, rib 252 becomes sacrificial tosupply a portion of the weld material as is well known in the art. Theend of tubular member 242 opposite to flange 250 defines enlargeddiameter end 108 which, as described above, is adapted to be connectedto the suitable conduit of the refrigeration system with whichcompressor 10 is to be utilized.

Valve member 94 is disposed within a chamber 256 formed by valve plate240 and upper cap 120. Upper cap 120 provides an annular stop surface orshoulder for restricting the movement of valve member 94. Valve member94 is sized so as to be freely movable between valve seat 98 and uppercap 120. The movement function and operation of valve member 94 indischarge valve assembly 232 is the same as that described above for theembodiment shown in FIGS. 1-4.

Referring now to FIG. 9, a discharge valve assembly 232′ according toanother embodiment of the present invention is illustrated. Valveassembly 232′ is shown welded to upper cap 120 extending throughaperture 122. Valve assembly 232′ is similar to valve assembly 232 shownin FIG. 8 except that tubular member 242 has been replaced with tubularmember 242′. Tubular member 242′ is similar to tubular member 242 exceptthat annular flange 250 and rib 252 have been replaced with annularflange 250′ and rib 252′. Annular flange 250′ is adapted to abut and bewelded to the inner surface of upper cap 120 radially inward of valveplate 240. Rib 252′ aids in the welding process to ensure a secure fluidtype seal. During the welding operation, rib 252′ becomes sacrificial tosupply a portion of the weld material as is well know in the art. Valvemember 94 is disposed within a chamber 256′ formed by valve plate 240and tubular member 242′. Flange 250′ of tubular member 242′ provides anannular stop surface or shoulder for restricting the movement of valvemember 94. Valve member 94 is sized so as to be freely movable betweenvalve seat 98 and flange 250′. The movement, function and operation ofvalve member 94 in discharge valve assembly 232′ is the same as thatdescribed above for the embodiment shown in FIGS. 1-4.

Referring now to FIG. 10, a discharge valve assembly 282 according toanother embodiment of the present invention is illustrated. Valveassembly 282 is shown welded to upper cap 120 extending through aperture122. Discharge valve assembly 282 comprises a discharge valve plateassembly 290, a tubular member 292 and valve member 94. Discharge valveplate assembly 290 comprises a discharge valve plate 294 and a tubularelement 296. Valve plate 294 is formed preferably from powdered metaland has the plurality of cutout portions 96 therein as well as valveseat 98. Valve plate 294 is secured to tubular element 296 by a formingoperation which sandwiches valve plate 294 within an annular groove 298of tubular element 296. Tubular element 296 is secured to tubularelement 292 by a brazing operation.

Tubular member 292 comprises a steel drawn tubular fitting 300 and atubular element 302. Steel fitting 300 is preferably friction welded toupper cap 120 to provide a secure fluid tight seal. Steel drawn fitting300 includes a reduced diameter portion 304 upon which tubular element296 of valve plate assembly 290 is brazed. Reduced diameter portion 304provides an annular stop surface or shoulder for restricting themovement of valve member 94. Tubular element 302 is brazed to aninternal diameter 306 of fitting 300. The end of tubular element 302opposite to fitting 300 defines enlarged diameter end 108 which, asdescribed above, is adapted to be connected to the suitable conduit ofthe refrigeration system with which compressor 10 is to utilized.

Valve member 94 is disposed within a chamber 308 formed by valve plateassembly 290 and tubular member 292. Valve member 94 is sized so as tobe freely movable between valve seat 98 and fitting 300. The movement,function and operation of valve member 94 in discharge valve assembly282 is the same as that described above for the embodiment shown inFIGS. 1-4.

Referring now to FIG. 11, a discharge valve assembly 332 according toanother embodiment of the present invention is illustrated. Valveassembly 332 is shown welded to upper cap 120 extending through aperture122. Discharge valve assembly 332 comprises a discharge valve plateassembly 340, a tubular element 342 and valve member 94. Discharge valveplate assembly 340 comprises a discharge valve plate 344, a cup shapedtubular fitting 346 and a stop 348. Valve plate 344 is formed preferablyfrom powdered metal and has the plurality of cutout portions 96 thereinas well as valve seat 98. Valve plate 344 is secured to tubular fitting346 by a forming operation which sandwiches valve plate 344 within anannular groove 350 of tubular fitting 346. Tubular fitting 346 and thusvalve assembly 332 is secured to upper cap 120 by being brazed to aformed flange 352 extending from upper cap 120 surrounding aperture 122.Stop 348 is a frusto-conical element which is brazed within tubularfitting 346 abutting an inwardly radially extending flange 354 oftubular fitting 346 to form an annular stop surface or shoulder forrestricting the movement of valve member 94.

Tubular element 342 is brazed to an internal diameter 356 of tubularfitting 346. The end of tubular element 342 opposite to fitting 346defines enlarged diameter end 108 which, as described above, is adaptedto be connected to the suitable conduit of the refrigeration system withwhich compressor 10 is to be utilized.

Valve member 94 is disposed within a chamber 358 formed by valve plateassembly 340. Valve member 94 is sized so as to be freely movablebetween valve seat 98 and stop 348. The movement, function and operationof valve member 94 in discharge valve assembly 332 is the same as thatdescribed above for the embodiment shown in FIGS. 1-4.

Referring now to FIG. 12, a discharge valve assembly 382 according toanother embodiment of the present invention is illustrated. Valveassembly 382 is shown welded to upper cap 120 extending through aperture122. Discharge valve assembly 382 comprises a valve plate assembly 390,a tubular element 392 and a valve member 94. Discharge valve plateassembly 390 comprises a discharge valve plate 394 and a tubular fitting396. Valve plate 394 is formed preferably from powdered metal and hasthe plurality of cutout portions 96 therein as well as valve seat 98.Valve plate 394 is secured to tubular fitting 396 by a forming operationwhich sandwiches valve plate 394 within an annular groove 398 of tubularfitting 396. Tubular fitting 396 has a generally radially outwardlyextending annular flange 400 which is adapted to abut and be welded tothe outer surface of upper cap 120. In order to aid in the weld processand ensure a secure fluid tight seal, an axially extending rib 402 isprovided on flange 400. During the welding operation, rib 402 becomessacrificial to supply a portion of the weld material as is well known inthe art.

Tubular element 392 comprises a tubular fitting 404 and a tube 406.Tubular fitting 404 is brazed to an internal diameter 408 of tubularfitting 396. The end of tubular fitting 404 extending within tubularfitting 396 forms an annular stop surface or shoulder for restrictingthe movement of valve member 94. Tube 406 is brazed to an internaldiameter 410 of fitting 404. The end of tube 406 opposite to fitting 404defines enlarged diameter end 108 which, as described above, is adaptedto be connected to the suitable conduit of the refrigeration system withwhich compressor 10 is to be utilized.

Valve member 94 is disposed within a chamber 412 formed by valve plateassembly 390 and tubular element 392. Valve member 94 is sized so as tobe freely movable between valve seat 98 and tubular fitting 404. Themovement, function and operation of valve member 94 in discharge valveassembly 382 is the same as that described above for the embodimentshown in FIGS. 1-4.

Referring now to FIG. 13, a discharge valve assembly 432 according toanother embodiment of the present invention is illustrated. Valveassembly 432 is shown welded to upper cap 120 extending out of aperture122. Valve assembly 432 comprises a discharge valve plate 440, anelongated tubular member 442 and valve member 94. Discharge valve plate440 is formed preferably from powdered metal and has the plurality ofcutout portions 96 therein as well as valve seat 98. Valve plate 440 issecured to tubular member 442 by being welded or brazed to an internaldiameter 444 of tubular member 442.

Tubular member 442 has a generally outwardly extending annular flange450 which is adapted to abut and be welded to the inside surface ofupper cap 120. In order to aid in the welding process and ensure asecure fluid tight seal, an outwardly projecting rib 452 is provided onflange 450. During the welding operation, rib 452 becomes sacrificial tosupply a portion of the weld material as is well known in the art.Tubular member 442 has a generally radially inwardly extending flange454 which with valve plate 440 forms a chamber 456 within which valvemember 94 is located. Flange 454 provides an annular stop surface orshoulder for restricting the movement of valve member 94. The end oftubular member 442 opposite to flange 450 defines enlarged diameter end108 which, as described above, is adapted to be connected to thesuitable conduit of the refrigeration system with which compressor 10 isto be utilized.

Valve member 94 is disposed within chamber 456 and is sized so as to befreely movable between valve seat 98 and flange 454. The movement,function and operation of valve member 94 in discharge valve assembly432 is the same as that described above for the embodiment shown inFIGS. 1-4.

Referring now to FIG. 14, a discharge valve assembly 482 according toanother embodiment of the present invention is illustrated. Valveassembly 482 is shown welded to upper cap 120 adjacent to aperture 122.Valve assembly 482 comprises a discharge valve plate 490, an elongatedtubular member 492 and valve member 94. Discharge valve plate 490 isformed preferably from powdered metal and has the plurality of cutoutportions 96 therein as well as valve seat 98. Valve plate 490 is securedto tubular member 492 by being welded or brazed to an internal diameter494 of tubular member 492.

Tubular member 492 has a generally outwardly extending annular flange500 which is adapted to abut and be welded to the outside surface ofupper cap 120. In order to aid in the welding process and ensure asecure fluid tight seal, an outwardly projecting rib 502 is provided onflange 500. During the welding operation, rib 502 becomes sacrificial tosupply a portion of the weld material as is well known in the art.Tubular member 492 has a generally radially inwardly extending flange504 which with valve plate 490 forms a chamber 506 within which valvemember 94 is located. Flange 504 provides an annular stop surface orshoulder for restricting the movement of valve member 94. The end oftubular member 492 opposite to flange 500 defines enlarged diameter end108 which, as described above, is adapted to be connected to thesuitable conduit of the refrigeration system with which compressor 10 isto be utilized.

Valve member 94 is disposed within chamber 506 and is sized so as to befreely movable between valve seat 98 and flange 504. The movement,function and operation of valve member 94 in discharge valve assembly482 is the same as that described above for the embodiment shown inFIGS. 1-4.

Referring now to FIG. 15, a discharge valve assembly 482′ according toanother embodiment of the present invention is illustrated. Valveassembly 482′ is the same as valve assembly 482 except that elongatedtubular member 492 of valve assembly 482 is replaced by tubular member492′ of valve assembly 482′. Tubular member 492′ is the same as tubularmember 492 except that the enlarged portion of tubular member 492′ isthe same as tubular member 492 except that the enlarged portion oftubular member 492′ adjacent upper cap 120 is modified for frictionwelding to upper cap 120 as is well known in the art. During the weldingoperation, the enlarged end of tubular member 492′ adjacent upper cap120 is curled over to form flange 500′ as is also well known in the art.The function and operation of valve assembly 482′ is the same as thatdescribed above for valve assembly 482.

Referring now to FIG. 16, a discharge valve assembly 532 according toanother embodiment of the present invention is illustrated. Valveassembly 532 is shown friction-welded to upper cap 120 extending throughaperture 122. Discharge valve assembly 532 comprises a discharge valveplate 540, a tubular member 542 and valve member 94. Tubular member 542includes a tubular fitting 544 and a valve body 546. Valve plate 540 ispreferably formed from powdered metal and has the plurality of cutoutportions 96 therein as well as valve seat 98. Valve plate 540 is securedto valve body 546 by an orbit-forming operation which sandwiches valveplate 540 within an annular groove 548 of valve body 546. Beforeforming, valve body 546 includes an annular extension which extendsbeyond the outer edge of valve plate 540. The annular extension isformed over the outside end of valve plate 540 to create a flange 550which retains valve plate 540 within valve body 546 similar to themanner shown in previous embodiments.

Tubular fitting 544 is designed to be friction welded to upper cap 120.Prior to the friction welding operation, valve body 546 is pressed intoan enlarged portion 554 of tubular fitting 544. Valve body 546 can bepressed into tubular fitting 544 before or after the assembly of valveplate 540 but preferably it is done before. The open end of enlargedportion 554 of tubular fitting 544 extends beyond a shoulder 556 formedon valve body 546 such that only enlarged portion 554 of tubular fitting544 contacts upper cap 120 before the welding operation. The open end ismodified for friction-welding as is well known in the art. During thewelding operation, the open end of enlarged portion 554 is curled overto form a flange 558 as is also known well in the art. The portion offlange 558 which extends into enlarged portion 554 retains valve body546 within fitting 544.

Valve member 94 is disposed within a chamber 560 formed by valve plate540 and valve body 546. Valve member 94 is sized so as to be freelymovable between valve seat 98 on valve plate 540 and valve body 546which acts as a stop for valve member 94. The movement function andoperation of valve member 94 in discharge valve assembly 532 is the sameas described above for the embodiment shown in FIGS. 1-4.

While the above detailed description describes the preferred embodimentof the present invention, it should be understood that the presentinvention is susceptible to modification, variation and alterationwithout deviating from the scope and fair meaning of the subjoinedclaims.

What is claimed is:
 1. A compressor assembly comprising: a shelldefining a discharge chamber; a compressor disposed within said shell,said compressor compressing a fluid from a suction pressure to adischarge pressure, fluid at said discharge pressure being directed tosaid discharge chamber; a discharge valve assembly attached to saidshell in communication with said discharge chamber, said discharge valveassembly comprising: a tubular member secured to said shell; a valveseat secured to said tubular member; a stop secured to said shell, saidstop and said valve seat defining a valve chamber; and a valve memberdisposed in said valve chamber, said valve member being movable betweena closed position where said valve member abuts said valve seat and anopen position where said valve member abuts said stop; wherein saidtubular member is secured to an outside surface of said shell, saidtubular member providing fluid flow between said discharge chamber andan environment outside said shell.
 2. A compressor assembly comprising:a shell defining a discharge chamber; a compressor disposed within saidshell, said compressor compressing a fluid from a suction pressure to adischarge pressure, fluid at said discharge pressure being directed tosaid discharge chamber; a discharge valve assembly attached to saidshell in communication with said discharge chamber, said discharge valveassembly comprising: a tubular member secured to said shell; a valveseat secured to said tubular member; a stop secured to said shell, saidstop and said valve seat defining a valve chamber; and a valve memberdisposed in said valve chamber, said valve member being movable betweena closed position where said valve member abuts said valve seat and anopen position where said valve member abuts said stop; wherein saidtubular member comprises: a tubular fitting secured to an outsidesurface of said shell, said tubular fitting providing fluid flow betweensaid discharge chamber and an environment outside said shell; and avalve body disposed between said tubular fitting and said shell, saidvalve seat being secured to said valve body.
 3. The compressor assemblyaccording to claim 2, wherein said stop is unitarily formed with saidvalve body.
 4. The compressor assembly according to claim 2, whereinsaid valve body is secured to said tubular fitting.
 5. The compressorassembly according to claim 2, wherein said valve body includes a flangefor securing said valve seat to said valve body.